Absorbent cores and methods for forming absorbent cores

ABSTRACT

Pulpless absorbent cores and methods of manufacture are disclosed. A method of forming an absorbent core may comprise moving a forming surface in a machine direction, creating a pressure differential across the forming surface, advancing a base carrier sheet on the forming surface in the machine direction, applying a first adhesive onto the base carrier sheet, and applying a first quantity of particulate material onto the first adhesive at a first cross-machine direction width. The method may further comprise depositing a matrix of material onto the first quantity of particulate material at a second cross-machine direction width, the matrix of material comprising a second quantity of particulate material and a second adhesive, wherein the second cross-machine direction width is smaller than the first cross-machine direction width, and wherein the second quantity of particulate material and the adhesive are pre-mixed prior to deposition onto the first quantity of particulate material.

The present application is a continuation application and claimspriority to U.S. patent application Ser. No. 16/086,038, filed on Sep.18, 2018, which is a national-phase entry, under 35 U.S.C. § 371, of PCTPatent Application No. PCT/US16/25190, filed on Mar. 31, 2016, all ofwhich are incorporated herein by reference.

FIELD OF THE INVENTION

The field of this disclosure relates generally to absorbent cores andmethods of manufacturing absorbent cores for use in absorbent articles,and more specifically to pulpless absorbent cores and methods of formingpulpless absorbent cores for use in absorbent articles, such as diapers,training pants, incontinence products, disposable underwear, medicalgarments, feminine care articles, absorbent swim wear, and the like.

BACKGROUND

Absorbent cores are used in different types of products to control andcontain bodily fluids and other bodily liquid discharge. Many presentabsorbent cores include pulp fluff, which acts to absorb the dischargedliquids. Present absorbent articles can also contain particulateabsorbent material, such as superabsorbent material, mixed in with thepulp fluff. The particulate absorbent material has a higher absorbentcapacity than the pulp fluff, and the inclusion of particulate absorbentmaterial can greatly increase the absorbent capacity of the absorbentcores. In these instances, the pulp fluff works not only to help absorbdischarged fluids, but also to stabilize the particulate absorbentmaterial, for instance maintaining the location of the particulateabsorbent material within the absorbent cores. However, the pulp fluffin these absorbent cores imparts a significant amount of bulk to theabsorbent cores. Accordingly, absorbent cores that have a high absorbentcapacity yet do not contain pulp fluff, or do not contain a substantialamount of pulp fluff, in order to reduce bulk may be desirable.

BRIEF SUMMARY OF THE INVENTION

This disclosure relates generally to absorbent cores and methods ofmanufacturing absorbent cores for use in absorbent articles, and morespecifically to pulpless absorbent cores and methods of forming pulplessabsorbent cores for use in absorbent articles, such as diapers, trainingpants, incontinence products, disposable underwear, medical garments,feminine care articles, absorbent swim wear, and the like.

In a first embodiment, a method for forming an absorbent core maycomprise moving a forming member in a machine direction, the formingmember having a foraminous forming surface, creating a pressuredifferential across the foraminous forming surface, advancing a basecarrier sheet on the foraminous forming surface in the machinedirection, applying a first adhesive onto the base carrier sheet, andapplying a first quantity of particulate material onto the firstadhesive at a first cross-machine direction width. In some embodiments,the method may further comprise depositing a matrix of material onto thefirst quantity of particulate material at a second cross-machinedirection width, the matrix of material comprising a second quantity ofparticulate material and a second adhesive, wherein the secondcross-machine direction width is smaller than the first cross-machinedirection width, and wherein the second quantity of particulate materialand the adhesive are pre-mixed prior to deposition onto the firstquantity of particulate material.

Additionally, or alternatively, in further embodiments according to thefirst embodiment, the method may further comprise applying a thirdadhesive onto the first quantity of particulate material beforedepositing the matrix of material onto the first quantity of particulatematerial.

Additionally, or alternatively, in further embodiments according to theabove embodiment, the third adhesive may comprise a spray applicationaqueous binder (SAAB) adhesive.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the first embodiment, themethod may further comprise applying a top carrier sheet onto the matrixof material.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the first embodiment, themethod may further comprise folding the base carrier sheet to form a topcarrier sheet.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the first embodiment, a thirdadhesive may be applied onto the matrix of material.

Additionally, or alternatively, in further embodiments according to theabove embodiment, the method may further comprise applying a top carriersheet onto the third adhesive.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the first embodiment, thesecond cross-machine direction width may have a value that is betweenone-quarter and three-quarters of a value of the first cross-machinedirection width.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the first embodiment, the basecarrier sheet may comprise a left edge region, a center region, and aright edge region, and the matrix of material may be depositedthroughout the center region such that the center region has a higherbasis weight than either of the first edge region and the second edgeregion.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the first embodiment, the basisweight of the center region may comprise between 150% and 400% of thebasis weight of either of the first edge region or the second edgeregion.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the first embodiment, at least33% of a total amount of particulate material of the absorbent core maybe disposed within the center region

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the first embodiment, themethod may further comprise applying cellulose fibers onto the basecarrier sheet.

Additionally, or alternatively, in further embodiments according to theabove embodiment, the cellulose fibers and the first quantity ofparticulate material are mixed together.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the first embodiment, the firstquantity of particulate material may comprise super absorbent material(SAM).

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the first embodiment, thesecond quantity of particulate material may comprise super absorbentmaterial (SAM).

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the first embodiment, thesecond quantity of particulate material may comprise at least 25%, byweight, of a total particulate material content of the absorbent core.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the first embodiment, thesecond quantity of particulate material may comprise at least 50%, byweight, of a total particulate material content of the absorbent core.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the first embodiment, thesecond quantity of particulate material may comprise at least 75%, byweight, of a total particulate material content of the absorbent core.

In a second embodiment, a method of forming an absorbent core maycomprise advancing a base carrier sheet on a foraminous forming memberin a machine direction, creating a pressure differential across theforaminous forming member, and depositing a matrix of material onto thebase carrier sheet at a first cross-machine direction width, the matrixof material comprising a first quantity of particulate material and afirst adhesive. In some additional embodiments, the method may furthercomprise applying a second quantity of particulate material onto thebase carrier sheet and the matrix of material at a second cross-machinedirection width, wherein the first cross-machine direction width issmaller than the second cross-machine direction width, and wherein thefirst quantity of particulate material and the adhesive are pre-mixedprior to deposition onto the base carrier sheet.

Additionally, or alternatively, in further embodiments according to thesecond embodiment, the method may further comprise applying a topcarrier sheet onto the second quantity of particulate material.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the second embodiment, thefirst cross-machine direction width may have a value that is betweenone-quarter and three-quarters of a value of the second cross-machinedirection width.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the second embodiment, thefirst cross-machine direction width may have a value that is betweenone-third and two-thirds of a value of the second cross-machinedirection width

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the second embodiment, themethod may further comprise injecting air toward streams of particulatematerial and adhesive to mix the streams of the particulate material andthe adhesive prior to the particulate material and the adhesive beingdeposited as a matrix of material at the forming surface.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the second embodiment, thefirst quantity of particulate material may further comprise cellulosefibers.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the second embodiment, thefirst quantity of particulate material may comprise super absorbentmaterial (SAM).

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the second embodiment, thesecond quantity of particulate material may comprise SAM.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the second embodiment, thesecond quantity of particulate material may comprise a mixture ofcellulose fibers and particulate material.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the second embodiment, themethod may further comprise applying a second adhesive onto the basecarrier sheet.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the second embodiment, themethod may further comprise applying a second adhesive onto the firstquantity of particulate material.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the second embodiment, themethod may further comprise applying a third adhesive onto the topcarrier sheet.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the second embodiment, theparticulate material within the matrix of material may comprise at least25%, by weight, of a total particulate material content of the absorbentcore.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the second embodiment, the basecarrier sheet may comprise a left edge region, a center region, and aright edge region, and the center region may have a higher basis weightthan either of the first edge region and the second edge region afterapplying the second quantity of particulate material.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the second embodiment, thebasis weight of the center region may comprise between 150% and 400% ofthe basis weight of either of the first edge region or the second edgeregion after applying the second quantity of particulate material.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the second embodiment, themethod may further comprise applying a second adhesive onto the secondquantity of particulate material.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the second embodiment, thesecond adhesive may comprise a spray application aqueous binder (SAAB)adhesive.

In a third embodiment, an apparatus for forming absorbent cores maycomprise a forming member having a forming surface that is moveable in amachine direction, the forming surface having a forming surface widthextending in a cross-machine direction, a first adhesive applicator, aparticulate material delivery chamber, the first particulate materialdelivery chamber comprising a first particulate material inletconfigured for dispensing a first quantity of particulate materialtowards the forming surface, and a matrix delivery assembly, the matrixdelivery assembly comprising a second particulate material inlet and oneor more adhesive applicator nozzles configured for dispensing a secondquantity of particulate material and adhesive toward the forming surfacein a manner such that the second quantity of particulate material andadhesive comingle before depositing at the forming surface.

Additionally, or alternatively, in further embodiments according to thethird embodiment, the particulate material delivery chamber may beconfigured for dispensing the first quantity of particulate materialtowards the forming surface such that the first quantity of particulatematerial is deposited at the forming surface at a first cross-machinedirection width, the matrix delivery assembly may be configured fordispensing the second quantity of particulate material and adhesivetoward the forming surface such that the second quantity of particulatematerial and adhesive are deposited at the forming surface at a secondcross-machine direction width, and the second cross-machine directionwidth may be less than the first cross-machine direction width.

Additionally, or alternatively, in further embodiments according to theabove embodiment, the second cross-machine direction width may have avalue that is between one-quarter and three-quarters of a value of thefirst cross-machine direction width.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect the third embodiment, the firstparticulate material delivery chamber may be disposed prior to thematrix delivery assembly in the machine direction.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect the third embodiment, the matrixdelivery assembly may be disposed prior to the particulate materialdelivery chamber in the machine direction.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect the third embodiment, theapparatus may further comprise a third adhesive applicator disposedafter the first adhesive applicator in the machine direction.

Additionally, or alternatively, in further embodiments according to theabove embodiment, the first adhesive applicator may be configured todispense hot-melt adhesive, and the third adhesive applicator may beconfigured to dispense a spray-application aqueous binder (SAAB)adhesive.

In a fourth embodiment, an absorbent core may comprise a base carriersheet, a first adhesive disposed directly onto at least a portion of thebase carrier sheet, a first quantity of particulate material disposed onthe first adhesive, a matrix of material comprising a second quantity ofparticulate material and adhesive disposed on the first quantity ofparticulate material, and a top carrier sheet disposed on the matrix ofmaterial.

Additionally, or alternatively, in further embodiments according to thefourth embodiment, the absorbent core may further comprise a secondadhesive disposed on the first quantity of particulate material.

Additionally, or alternatively, in further embodiments according to theabove embodiment, the absorbent core may further comprise a thirdadhesive disposed on the matrix of material.

Additionally, or alternatively, in further embodiments according to thefourth embodiments according to any of the above embodiments withrespect to the fourth embodiment, the absorbent core may furthercomprise a second adhesive disposed on the matrix of material.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the fourth embodiment, thefirst quantity of particulate material may further comprise cellulosefibers.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the fourth embodiment, thefirst quantity of particulate material may comprise superabsorbentmaterial (SAM).

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the fourth embodiment, thesecond quantity of particulate material may comprise SAM.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the fourth embodiment, the basecarrier sheet and the top carrier sheet may comprise a single carriersheet.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the fourth embodiment, theabsorbent core may have a machine direction length and a cross-machinedirection width, and wherein a cross-machine direction width of thematrix of material may be less than a cross-machine direction width ofthe first quantity of particulate material.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the fourth embodiment, thesecond quantity of particulate material may comprise at least 25%, byweight, of a total particulate material content of the absorbent core.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the fourth embodiment, thesecond quantity of particulate material may comprise at least 50%, byweight, of a total particulate material content of the absorbent core.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the fourth embodiment, thesecond quantity of particulate material in the matrix layer may compriseat least 75%, by weight, of a total particulate material content of theabsorbent core.

In a fifth embodiment, an absorbent core may comprise one or more outersheets forming an enclosure, the one or more outer sheets having anexternally oriented face and an internally oriented face, a firstquantity of particulate material disposed within the enclosure, and amatrix of material comprising a second quantity of particulate materialand adhesive disposed adjacent the first quantity of particulatematerial within the enclosure.

Additionally, or alternatively, in further embodiments according thefifth embodiment, the absorbent core may further comprise an adhesivedisposed between the first quantity of particulate material and theinternally oriented face of the enclosure.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the fifth embodiment, theabsorbent core may further comprise an adhesive disposed between thematrix of material and the internally oriented face of the enclosure.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the fifth embodiment, thesecond quantity of particulate material may comprise at least 25%, byweight, of a total particulate material content of the absorbent core.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the fourth embodiment, thesecond quantity of particulate material may comprise at least 50%, byweight, of a total particulate material content of the absorbent core.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the fourth embodiment, thesecond quantity of particulate material may comprise at least 75%, byweight, of a total particulate material content of the absorbent core.

In a sixth embodiment, an absorbent core may comprise a base carriersheet having a carrier sheet cross-machine direction width, a firstadhesive disposed directly on the base carrier sheet, a first quantityof particulate material disposed on the first adhesive, the firstquantity of particulate material having a first particulatecross-machine direction width, a matrix of material comprising a secondquantity of particulate material and adhesive disposed on the firstquantity of particulate material, the matrix of material having a matrixcross-machine direction width, and a top carrier sheet disposed on thematrix of material. In some further embodiments, the matrix of materialcross-machine direction width may be less than the first particulatecross-machine direction width.

Additionally, or alternatively, in further embodiments according thesixth embodiment, the absorbent core may further comprise a secondadhesive disposed directly on the first quantity of particulate materialbetween the first quantity of particulate material and the matrix layerof material.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the sixth embodiment, theabsorbent core may further comprise a second adhesive disposed on thematrix of material between the matrix of material and the top carriersheet.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the sixth embodiment, the firstadhesive and the second adhesive may comprise different adhesives.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the sixth embodiment, the firstadhesive may comprise a holt-melt adhesive.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the sixth embodiment, thesecond adhesive may comprise hot-melt adhesive.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the sixth embodiment, thesecond adhesive may comprise a spray application aqueous-binder (SAAB)adhesive.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the fifth embodiment, the firstquantity of particulate material may further comprise cellulose fibers.

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the sixth embodiment, the firstquantity of particulate material may comprise superabsorbent material(SAM).

Additionally, or alternatively, in further embodiments according to anyof the above embodiments with respect to the sixth embodiment, thesecond quantity of particulate material may comprise SAM.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of an example forming assembly for formingabsorbent cores.

FIG. 2 is a perspective view of an exemplary forming drum that may beused in the assembly of FIG. 1.

FIG. 3 is a side view of an example forming drum and associatedcomponents that may be used in the assembly of FIG. 1.

FIG. 4A is a side view of an exemplary particulate absorbent materialdelivery chamber that may be used in the assembly of FIG. 1.

FIG. 4B is a front view of an exemplary particulate absorbent materialdelivery chamber that may be used in the assembly of FIG. 1.

FIG. 5 is an illustration of an exemplary absorbent core structure thatmay be produced by the assembly of FIG. 1.

FIG. 6A is a cross-section view of an exemplary absorbent core that maybe produced by the assembly of FIG. 1.

FIG. 6B is a cross-section view of an alternative exemplary absorbentcore that may be produced by the assembly of FIG. 1.

FIG. 7 is an alternative schematic of an example forming assembly forforming absorbent cores.

FIG. 8 is a cross-section view of an alternative exemplary absorbentcore that may be produced by the assembly of FIG. 1 or FIG. 7.

FIG. 9 is a perspective view of a forming drum including a plurality ofmasking members for forming shaped absorbent cores.

FIG. 10 is a top view of a masking member disposed on the forming drumof FIG. 9.

FIG. 11 is an illustration of an exemplary shaped absorbent corestructure that may be produced using the forming drum and maskingmembers of FIGS. 9 and 10.

FIG. 12 is a schematic of an example forming assembly for formingabsorbent cores including both pulp fluff and particulate absorbentmaterial.

FIG. 13 depicts a cross-section of an exemplary absorbent core that mayfor formed by the forming assembly of FIG. 12.

FIGS. 14A and 14B are illustrations of carrier sheets that may be usedto form absorbent cores.

FIGS. 15A and 15B depict top-down internal schematic views of exemplarycomponents that may be used to form a matrix layer of particulateabsorbent material and adhesive.

FIG. 16 is a side-view of the exemplary components of FIG. 15A.

FIG. 17 is an illustration of a length of formed absorbent cores thatmay be formed using the components of FIG. 15A.

FIG. 18 depicts a cross-section of an exemplary absorbent core takenalong line B-B′ in FIG. 17 which includes a matrix layer.

FIG. 19 depicts a cross-section of another exemplary absorbent coretaken along line B-B′ in FIG. 17 which includes a matrix layer.

DETAILED DESCRIPTION OF THE DRAWINGS

When introducing elements of the present invention or the preferredembodiment(s) thereof, the articles “a”, “an”, “the” and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements. Moreover, the use of “top”, “bottom”, “above”, “below” andvariations of these terms is made for convenience, and does not requireany particular orientation of the components.

With reference now to the drawings, FIG. 1 depicts a schematic drawingof an example absorbent core forming apparatus 20, which may be used toform absorbent cores. A few components of apparatus 20 include theforming drum 26 and the particulate material delivery chambers 60 a, 60b. Accordingly, in some embodiments, apparatus 20 may be used to formabsorbent cores comprising particulate material. Superabsorbent material(SAM) is one example of particulate material contemplated by thisdisclosure. In at least some of these embodiments, the particulatematerial content of the formed absorbent cores may comprise themajority, by weight, of the contents of the absorbent cores. In otherembodiments, the particulate material content of the formed absorbentcores may comprise between 90%-100%, by weight, of the contents of theabsorbent cores. These absorbent cores may be described herein aspulpless absorbent cores. As used herein, the phrase pulpless absorbentcores may include both absorbent cores that are truly pulpless andabsorbent cores that are only substantially pulpless which havecellulose fibers comprising between 0.5%-10%, by weight, of the totalcontents of the absorbent cores. Pulpless cores may have one or moreadvantages relative to absorbent cores that have higher cellulose fibercontent. For example, pulpless cores can have absorbent properties, suchas absorbent capacity, similar to cores with higher cellulose fibercontent. However, pulpless cores can have smaller dimensions than coreshaving cellulose fiber pulp content. In particular, the pulpless coresmay have a reduced thickness in comparison to cores with highercellulose fiber content.

In the exemplary embodiment of FIG. 1, a base carrier sheet 70 may beunwound from a carrier sheet roll 72. One or more material handlingrollers 74 may be used to transport the base carrier sheet 70 proximateforming drum 26. Once in proximity to forming drum 26, the base carriersheet 70 may be drawn to forming drum 26 by vacuum pressure, describedin more detail below in relation to FIGS. 2 and 3. The forming drum 26rotates in the direction of arrow 10, about drive-shaft 28, advancingthe base carrier sheet 70 through one or more absorbent core formingstages, ultimately resulting in the absorbent cores 101. Althoughabsorbent cores 101 are shown as discrete pads, in other embodiments,absorbent cores 101 may be formed as a continuous ribbon.

In some embodiments, the base carrier sheet 70 may comprise a nonwovenmaterial such as a meltblown, spunbond-meltblown-spunbond (SMS),spunlace material, or a natural tissue material. However, in otherembodiments, any suitable non-woven material may be used. The basecarrier sheet 70 should be at least semi-permeable to air-flow. Forinstance, the base carrier sheet 70 should be sufficiently permeablesuch that air is be able to move through the base carrier sheet 70 froma top surface disposed away from the forming surface 24 to a bottomsurface disposed proximate the forming surface 24, and ultimatelythrough forming surface 24 into the interior of forming drum 26. Someexample suitable dimensions of the base carrier sheet 70 include a widthbetween about 7 cm to about 36 cm. Some example suitable basis weightsfor the base carrier sheet 70 range from about 5 grams per square meter(gsm) to about 50 gsm. However, the specific dimensions and basisweights used for the base carrier sheet 70 may differ, even outside ofthese ranges, based on the specific application or desired propertiesfor the absorbent cores 101.

In the example of FIG. 1, the base carrier sheet 70 first moves throughfirst adhesive application zone 80, where adhesive applicator 76 appliesadhesive 78 to the base carrier sheet 70. In some examples, the adhesive78 may be a hot-melt adhesive, such as either a contact hot-meltadhesive or a non-contact hot-melt adhesive. Although, in otherexamples, adhesive 78 may be any other suitable adhesive for applicationon a carrier sheet. Further, adhesive 78 may be applied using anysuitable application technique or techniques. For instance, adhesive 78may be applied with a spray application, with a slot-coat application,or by any other appropriate application technique.

After exiting first adhesive application zone 80, the base carrier sheet70, now containing adhesive 78, is brought in proximity to forming drum26, where the base carrier sheet 70 is drawn to the forming drum throughvacuum pressure. The base carrier sheet then enters particulate materialdelivery chamber 60 a. Inside of particulate material delivery chamber60 a, particulate material may be deposited onto the base carrier sheet70. More specifically, the particulate material may be deposited ontoadhesive 78, where the particulate material becomes stabilized, orimmobilized on the base carrier sheet 70, by adhesive 78.

The hopper 90 in FIG. 1 may contain particulate material that isdelivered to the particulate material delivery chambers 60 a, 60 b. Theconnecting pipe 68 may connect directly to the hopper 90 in order totransport the particulate material from the hopper 90 to the particulatematerial delivery chambers 60 a, 60 b. In at least some embodiments, theconnecting pipe 68 may include metering device 92. The metering device92 may be any sort of bulk material metering device, based onvolumetric, gravimetric, or mass flow principles, or the like. Themetering device 92 may ensure that only a specified amount (forinstance, by volume or by weight) of particulate material flows throughthe connecting pipe per unit of time. Some example suitable ranges forthe volume of particulate material flowing through the metering device92 are between about 5,000 grams per minute (g/min) and about 25,000g/min. In this manner, the metering device 92 can help to ensure aproper amount of particulate material is delivered to particulatematerial delivery chambers 60 a, 60 b.

In the example shown in FIG. 1, the connecting pipe 68 may split intodelivery pipes 64 and 66. Each of the delivery pipes 64 and 66 may enterthe particulate material delivery chambers 60 a, 60 b, formingparticulate material delivery conduits 62 a, 62 b. The particulatematerial delivered to the particulate material delivery chambers 60 a,60 b may exit the particulate material delivery conduits 62 a, 62 b andbe deposited onto the adhesive 78 and the base carrier sheet 70. In somealternative embodiments, instead of a single metering device 92,multiple metering devices may be used to ensure proper delivery ofparticulate material to each of the particulate material deliverychambers 60 a, 60 b. For example, each of the delivery pipes 64 and 66may include a metering device, represented by the dashed boxes 93 a and93 b in FIG. 1, instead the apparatus 20 including metering device 92.

After exiting the particulate material delivery chamber 60 a, the basecarrier sheet 70, now containing adhesive 78 and particulate material,may enter second adhesive application zone 81. In some embodiments,second adhesive application zone 81 may be similar to first adhesiveapplication zone 80. For example, in second adhesive application zone81, adhesive applicator 86 may apply adhesive 88 to the base carriersheet 70. More specifically, adhesive applicator 86 may apply adhesive88 onto the particulate material that is stabilized on the base carriersheet 70. In some embodiments, adhesive 88 may be the same as adhesive78. For instance, adhesive 88 may also be a hot-melt adhesive, such as anon-contact hot-melt adhesive. Adhesive 88 may also be applied to thebase carrier sheet 70 in a similar manner as adhesive 78 was applied tothe base carrier sheet 70, such as with a spray application. Although,in other embodiments, adhesive 88 may be a different type of adhesivethan adhesive 78 and/or may be applied in a different manner thanadhesive 78.

In still other embodiments, adhesive 88 may not be a hot-melt adhesive.In some embodiments, adhesive 88 may be a spray-application aqueousbinder (SAAB) adhesive. Where adhesive 88 is a SAAB adhesive, adhesive88 may be applied with a spray-application. Implementing adhesive 88 asa SAAB adhesive may be preferable in certain embodiments, as SAABadhesives may be able to better penetrate particulate material thanhot-melt adhesives, thereby allowing for greater stabilization of theparticulate material deposited onto the base carrier sheet 70.

After passing through second adhesive application zone 81, the basecarrier sheet 70 now includes a first adhesive, adhesive 78, disposed onthe base carrier sheet 70, a first amount of particulate material 89 (ascan be seen in further detail in FIG. 6A) disposed on the adhesive 78,and a second adhesive, adhesive 88, disposed on the first amount ofparticulate material. The base carrier sheet 70 then enters theparticulate material delivery chamber 60 b. In the particulate materialdelivery chamber 60 b, a second amount of particulate material isdeposited onto adhesive 88 in a similar manner as particulate materialwas deposited onto adhesive 78 in the particulate delivery chamber 60 a.

In some embodiments, the particulate material delivered to the basecarrier sheet 70 in the particulate material delivery chambers 60 a, 60b may be the same type of particulate material. In other embodiments,however, the type of particulate material delivered to the base carriersheet 70 in the particulate material delivery chamber 60 a may bedifferent than the type of particulate material delivered to the basecarrier sheet 70 in the particulate material delivery chamber 60 b. Insuch embodiments, apparatus 20 may have two separate hoppers that eachstore different types of particulate material, in contrast to theexample of FIG. 1. Additionally, separate connecting and delivery pipesmay connect to each of the hoppers and to each of the particulatematerial delivery chambers 60 a, 60 b to maintain separation of thedifferent particulate material types. Alternatively, apparatus 20 maystill include only the single hopper 90 and the connecting and deliverypipes 68, 64, and 66, as shown in FIG. 1. In such embodiments, thehopper 90 may have two separate internal compartments to maintainseparation of the different particulate material types. Additionally,connecting pipe 68 may include separate internal lumens. A first of theinternal lumens may connect to a first internal compartment of thehopper 90 and to delivery pipe 64, while a second of the internal lumensmay connect to a second internal compartment of the hopper 90 and todelivery pipe 66.

As mentioned previously, in some embodiments the particulate materialmay comprise superabsorbent material (SAM). Suitable superabsorbentmaterials are well known in the art and are readily available fromvarious suppliers. Example suitable superabsorbent materials may includeBASF 9700, available from BASF Corporation, a business having officeslocated in Charlotte, N.C., U.S.A; and Evonik 5600, available fromEvonik Industries, a business having offices located in Parsippany,N.J., U.S.A.

In other embodiments, the particulate material may comprise low- ornon-absorbent material such as charcoal, sugar (e.g. xylitol or thelike), or encapsulated material. Accordingly, this disclosurecontemplates in any of the disclosed embodiments that the deliveredparticulate material may be either an absorbent material, anon-absorbent material, or both. For instance, absorbent particulatematerial may be mixed with non-absorbent particulate material, or afirst of the particulate material delivery chambers 60 a, 60 b maydeliver absorbent particulate material and a second of the particulatematerial delivery chambers 60 a, 60 b may deliver non-absorbentparticulate material.

Once the second amount of particulate material has been deposited ontothe base carrier sheet 70, a top carrier sheet 75 may be applied ontothe second amount of particulate material. The top carrier sheet 75 maybe unwound from a roll 77 of top carrier sheet material, and may betransported proximate the forming drum 26 via one or more materialhandling rollers 79. After the top carrier sheet 75 has been appliedonto the second amount of particulate material, the edges of the topcarrier sheet 75 and the base carrier sheet 70 may be bonded together(not shown) to form the pulpless absorbent cores 101. The absorbentcores 101 may then be transported on conveyer 95 for further processing.

In some embodiments, material handling roller 79 may also perform afunction similar to a nip roller. For instance, material handling roller79 may come into close proximity to conveyer 95 in region 99 and theabsorbent core 101 may be compressed to reduce bulk and/or to moresecurely bond the portions of the absorbent core 101 together. In otherembodiments, however, one or more separate rollers may perform a nipfunction, such as rollers 85.

In some alternative embodiments, a third adhesive may be applied to thesecond amount of particulate material before the top carrier sheet 75 isapplied to the second amount of particulate material. In some of theseembodiments, apparatus 20 may further include third adhesive applicationzone 91 a. Where apparatus 20 includes third adhesive application zone91 a, adhesive applicator 96 a may apply adhesive 98 a to the secondamount of particulate material before the top carrier sheet 75 isapplied. In various embodiments, adhesive 98 a may be similar to eitheradhesive 78 or adhesive 88 described previously, and may be applied inany of the previously described methods. In different embodiments,however, apparatus 20 may include third adhesive application zone 91 binstead of third adhesive application zone 91 a. In these embodiments,adhesive applicator 96 b may apply adhesive 98 b directly to the topcarrier sheet 75, instead of onto the second amount of particulatematerial. Additionally, adhesive 98 b may be similar to either adhesive78 or adhesive 88 described previously, except that adhesive 98 b maynot be a SAAB adhesive, as SAAB adhesives may not be suitable for directapplication to carrier sheets. Further, adhesive 98 a may be applied inany of the previously described methods. This third adhesive, applied byeither adhesive applicator 96 a or adhesive applicator 96 b, may furtherhelp to stabilize the second amount of particulate material and/or tomore securely attach the top carrier sheet 75 to the second amount ofparticulate material.

The adhesive applicators 76, 86, and/or 96 a or 96 b may be configuredto apply adhesive in a continuous manner in some embodiments. In otherembodiments, however, the adhesive applicators 76, 86, and/or 96 a or 96b may be configured to apply adhesive in an intermittent fashion. Forinstance, the adhesive applicators 76, 86, and/or 96 a or 96 b may beapplied intermittently to target zones on the base carrier sheet 70 tohelp stabilize the particulate material at locations on the base carriersheet that will be most effective in absorbing liquid in the resultingabsorbent cores due to the placement of the absorbent cores within anabsorbent article.

Additionally, in at least some embodiments, the adhesive applicators 76,86, and/or 96 a or 96 b may apply adhesive in a coordinated,intermittent fashion. In these embodiments, the adhesive applicator 86may apply adhesive intermittently in a fashion such that the adhesiveapplicator 86 applies adhesive on top of the adhesive applied byadhesive applicator 76. After application of adhesive by the adhesiveapplicator 86, the adhesive applied by the adhesive applicator 86 wouldoverlay the adhesive applied by the adhesive applicator 76. Inembodiments that include adhesive applicator 96 a or 96 b, the adhesiveapplicator 96 a or 96 b may apply adhesive in an intermittent fashionsuch that the adhesive applied by the adhesive applicator 96 a or 96 boverlays the adhesive applied by the adhesive applicator 76 and theadhesive applied by the adhesive applicator 86.

FIGS. 2 and 3 more closely depict portions of apparatus 20, includingforming drum 26. The forming drum 26 includes a movable, foraminousforming surface 24, indicated by the hatched pattern in FIG. 2,extending around the circumference of the forming drum 26. The formingdrum 26 is mounted on a drive shaft 28 and supported by bearings 30 (ascan be seen in FIG. 3). The forming drum 26 includes a circular drumwall (not shown) operatively connected to and rotated by the drum driveshaft 28. The shaft 28 is driven in rotation by a suitable motor or lineshaft (not shown) in a clockwise direction as depicted by the arrows inFIG. 3. In some embodiments, the drum wall can be a primary,load-bearing member, and the drum wall can extend generally radially andcircumferentially about the drum drive shaft 28.

A vacuum duct 36 located radially inwardly of the forming surface 24extends over an arc of the interior of the forming drum 26. The vacuumduct 36 is in fluid communication with the forming surface 24 fordrawing air through the forming surface 24. The vacuum duct 36 ismounted on and in fluid communication with a vacuum supply conduit 40connected to a vacuum source 42. The vacuum source 42 may be, forexample, an exhaust fan and may create a vacuum within the forming drumwhich may be between about 2 inches of H₂O to about 40 inches of H₂O.Beyond helping the base carrier sheet 70 adhere to the forming drum 26as the base carrier sheet 70 advances around the forming drum, thevacuum pressure created by the vacuum source 42 may help to pull theparticulate material exiting the particulate material delivery conduits62 a, 62 b toward the forming surface 24. This vacuum pressure may helpto spread the particulate material out on the forming surface 24 and tohelp form a more even distribution of the particulate material along thecross-machine direction 56 of the base carrier sheet 70.

The vacuum duct 36 is connected to the vacuum supply conduit 40 along anouter peripheral surface of the vacuum supply conduit 40, and extendscircumferentially about at least a portion of the vacuum supply conduit40. The vacuum duct 36 projects radially outwardly from the vacuumsupply conduit 40 toward the forming surface 24 and includes axiallyspaced side walls 34 and angularly spaced end walls 46.

The shaft 28 extends through the drum wall and into the vacuum supplyconduit 40 where it is received in the bearing 30. The bearing 30 issealed with the vacuum supply conduit 40 so that air is not drawn inaround the shaft 28 where it enters the vacuum supply conduit 40.

As representatively shown, the vacuum supply conduit 40 can include aconduit end wall 48 and a peripheral wall 50 that delimit the size andshape of the vacuum supply conduit 40. The vacuum supply conduit 40 canhave any suitable cross-sectional shape. In the illustratedconfiguration, the vacuum supply conduit 40 has a generally circularcross-sectional shape. The vacuum supply conduit 40 can be operativelyheld in position with any suitable support structure. The supportstructure can also be joined and connected to further components ormembers that operatively support the portions of the vacuum supplyconduit 40 structure that engage the drum drive shaft 28. For example,in the exemplary embodiment, one or more supports may connect to thebearing 30, and the entire vacuum supply conduit 40 may be supported byan overhead mount (not shown).

In the illustrated embodiment, walls 34 extend generally radially andcircumferentially about the vacuum supply conduit 40. A drum rim 52 isjoined to the walls 34 and is constructed and arranged to provide asubstantially free movement of air through the thickness of the drum rim52. The drum rim 52 is generally cylindrical in shape and extends alongthe direction of the drum axis 53, and circumferentially about the drumaxis 53. As representatively shown, the drum rim 52 can be supported byand extend between the walls 34.

With reference to FIGS. 2 and 3, the forming surface 24 can be providedalong the outer, cylindrical surface of the forming drum 26, and canextend along the axial and circumferential dimensions of the formingdrum. The circumferential dimension is generally in a machine direction54 and the axial dimension is generally in a cross-machine direction 56.The structure of the forming surface 24 can be composed of an assembly,and can include a foraminous member 58, which is operatively connectedand joined to the forming drum 26. In some contemplated embodiments, theforaminous member 58 may be comprised of a system of multiple inserts.Exemplary foraminous members that may be used in conjunction with thepresent disclosure are further described in U.S. Pat. No. 6,630,088,titled “Forming media with enhanced air flow properties”, filed on Oct.23, 2000.

The forming surface 24 can be operatively held and mounted on the drumrim 52 by employing any suitable attachment mechanism. As onerepresentative example, a system of nuts and bolts can be employed tosecure the forming surface 24 onto an operative set of mounting rings.In such an example, the mounting rings can be operatively mounted on andsecured to the drum rim 52. In other embodiments, the foraminous member58 may be integral with forming drum 26.

Although not shown in FIG. 2, one or more masking plates may be attachedto forming drum 26 on top of forming surface 24, as described in moredetail below. The masking plates, for example, may be attached to drumrim 52, or alternately to the foraminous forming member 58. The maskingplates may cover a portion of the forming surface 24 in order to blockthe vacuum in particular portions of the forming surface. The maskingplates may allow for differently shaped absorbent cores to be formed onthe forming drum 26, as will be explained in more detail below.

Suitable forming drum systems for use with the present disclosure arewell known in the art. For example, see U.S. Pat. No. 4,666,647 entitledAPPARATUS AND METHOD FOR FORMING A LAID FIBROUS WEB by K. Enloe et al.which issued May 19, 1987; and U.S. Pat. No. 4,761,258 entitledCONTROLLED FORMATION OF LIGHT AND HEAVY FLUFF ZONES by K. Enloe whichissued Aug. 2, 1988; the entire disclosures of which are incorporatedherein by reference in a manner that is consistent herewith. Otherforming drum systems are described in U.S. Pat. No. 6,330,735, entitledAPPARATUS AND PROCESS FOR FORMING A LAID FIBROUS WEB WITH ENHANCED BASISWEIGHT CAPABILITY by J. T. Hahn et al. which issued Dec. 18, 2001, theentire disclosure of which is incorporated herein by reference in amanner that is consistent herewith. Systems for forming surfaces aredescribed in U.S. Pat. No. 6,3630,088, entitled FORMING MEDIA WITHENHANCED AIR FLOW PROPERTIES by Michael Barth Venturino et al. whichissued Oct. 7, 2003, the entire disclosure of which is incorporatedherein by reference in a manner that is consistent herewith.

With respect to FIG. 3, additional features of the particulate materialdelivery chambers 60 a, 60 b are evident. For instance, the particulatematerial delivery chambers 60 a, 60 b further depict the particulatematerial delivery conduits 62 a, 62 b terminating in inlets 61 a, 61 b.The inlets 61 a, 61 b, e.g. the plane of the opening of the particulatematerial delivery conduits 62 a, 62 b, may be positioned within theparticulate material delivery chambers 60 a, 60 b such that the inlets61 a, 61 b are generally parallel with ground 94 and/or with the base ofthe forming drum 87. In these embodiments, the particulate materialdelivered from the inlets 61 a, 61 b may exit the inlets 61 a, 61 b in astream that is substantially perpendicular to the ground 94 and/or thebase of the forming drum 87. Additionally, the particulate materialdelivery chambers 60 a, 60 b are both situated on the top half of theforming drum 26. In this configuration, the particulate materialdelivered from the particulate material delivery chambers 60 a, 60 b mayfall with gravity towards the forming drum, instead of requiringadditional energy to push the particulate material to the forming drum26 against gravity.

However, in other embodiments, the inlets 61 a, 61 b may be tilted withrespect to the ground 94 and/or the base of the forming drum 87. Forinstance, the inlets 61 a, 61 b may form an angle 97 with respect to theground 94 and/or the base of the forming drum 87 (shown only withrespect to inlet 61 a in FIG. 3) having a value of between about 1degree and about 45 degrees. In even further embodiments, the inlets 61a, 61 b may form an angle 97 with respect to the ground 94 and/or thebase of the forming drum 87 such that the inlets 61 a, 61 b aretangential to the forming drum 26.

FIGS. 4A and 4B depict different close-up views of particulate materialdelivery chamber 60 a. FIG. 4A depicts a close-up of particulatematerial delivery chamber 60 a as viewed in the machine direction 54.FIG. 4A further depicts individual particulate material particles 89exiting inlet 61 a of particulate material delivery conduit 62 a andbeing deposited onto the base carrier sheet 70. The individualparticulate material particles 89 can also be seen disposed andstabilized on the portion of the base carrier sheet 70 after theparticulate material delivery chamber 60 a in the machine direction 54.

As mentioned previously, the particulate material may be deliveredthrough particulate material delivery conduit 62 a from the hopper 90,which results in the particulate material being gravity fed to inlet 61a. In some embodiments, the individual particulate material particles 89exiting inlet 61 a may exit with a velocity that is less than 1200meters per minute (m/min). In other embodiments, the individualparticulate material particles 89 exiting inlet 61 a may exit with avelocity that is less than 900 m/min. In still other embodiments, theindividual particulate material particles 89 exiting inlet 61 a may exitwith a velocity that is less than 600 m/min. In yet other embodiments,the individual particulate material particles 89 exiting inlet 61 a mayexit with a velocity that is less than 300 m/min. These velocities arein contrast to particulate material that is introduced to a formingchamber pneumatically. Where particulate material is introducedpneumatically, the minimum possible introduction velocity is over 1200m/min, because that is the velocity at which air needs to move in orderto move particulate material particles. Accordingly, gravity feeding theparticulate material into the particulate material delivery chamber 60 aallows the individual particulate material particles 89 to be introducedproximate the forming drum 26 with a relatively lower velocity than ifthe particulate material were to be pneumatically introduced. This lowerintroduction velocity may allow the individual particulate materialparticles 89 to be influenced to a greater extent by the vacuum pressureof the forming drum 26. In this manner, the apparatus 20 may be able toachieve a more even distribution of the individual particulate materialparticles 89 on the base carrier sheet 70 throughout the cross-machinedirection 56 than if the individual particulate material particles 89 weintroduced into the particulate material delivery chamber 60 apneumatically.

FIG. 4B depicts an internal view of particulate material deliverychamber 60 a as viewed from the cross-machine direction 56. As can beseen in FIG. 4B, the forming drum 26 may have a drum width 110, and theforming surface 24 may have a forming surface width 111. Generally, thedrum width 110 will be greater than the forming surface width 111, asthe forming drum 26 will include drum rim 52. However, this is notnecessary in all embodiments. FIG. 4B also depicts the forming surface24 as a relatively uniform and continuous surface. As mentionedpreviously, an as will be described in more detail below, in differentembodiments one or more masking plates may obscure portions of theforming surface 24.

Also shown in FIG. 4B is the particulate material delivery conduit 62 aand inlet 61 a having an inlet width 112. In some embodiments, the inletwidth 112 may be the same as the forming surface width 111. However, inother embodiments, the inlet width 112 may be smaller or greater thanthe forming surface width 111. For instance, the inlet width 112 may bethe same as the drum width 110. In other examples, the inlet width 112may smaller than the forming surface width 111, such as be between aboutone-quarter and about nine-tenths of the forming surface width 111.Additionally, inlet width 112 may be different for each of particulatematerial delivery conduits 62 a, 62 b.

The particulate material delivery conduit 62 a may further having avertical conduit spacing 114 comprising an amount of space between theinlet 61 a of the particulate material delivery conduit 62 a and theforming surface 24. In some examples, the vertical conduit spacing 114may be between about 15 cm to about 100 cm.

As shown in FIG. 4B, the particulate material delivery chamber 60 a maynot be sealed against the forming drum 24. For instance, there may be agap between the bottom edges 113 of the particulate material deliverychamber 60 a and the forming surface 24 or the forming drum 26. The gapmay have a gap space 116 that can be between about 0.5 cm and about 5cm. In these embodiments, air may be able to enter into the particulatematerial delivery chamber 60 a through gap space 116, as shown by arrows117. Entry of air into the particulate material delivery chamber 60 amay push the particulate material 89 toward a center of the formingsurface 24 as the particulate material falls from the inlet 61 a to theforming surface 24. This may result in a cross-direction 56 width of theparticulate material 89 deposited at the forming surface 24 that is lessthan inlet width 112. This may result in more particulate material 89present in a central region of formed absorbent cores than if there wereno gap space 116. In some alternative embodiments, gap space 116 may notbe disposed between the bottom edges 113 of the particulate materialdelivery chamber 60 a and the forming surface 26. Rather, the bottomedges 113 of the particulate material delivery chamber 60 a may besealed against the forming drum 26, and a separate hole may be disposedthrough a side wall of the particulate material delivery chamber 60 a toallow entry of air into the particulate material delivery chamber 60 a.

Accordingly, in other embodiments, there may not be a gap space 116between the bottom edges 113 of the particulate material deliverychamber 60 a and the forming surface 24 or the forming drum 26. Forinstance, the bottom edges 113 of the particulate material deliverychamber 60 a may contact the forming surface 24 or the forming drum 26,or one or more gap fillers (not shown) may be positioned to close up thegap space 116. In these embodiments, there may be no air entering gapspace 116. Accordingly, there may be no air impinging on the stream ofparticulate material 89 and pushing the particulate material 89 inwardfrom the edges of the forming surface 24. In these embodiments, thecross-direction 56 width of the particulate material 89 deposited at theforming surface 24 may be close or equal to the inlet width 112.

In some additional or alternative embodiments, an upper region of theparticulate material delivery chamber 60 a may be open and may allow airto flow into the particulate material delivery chamber 60 a as shown byarrows 119. In these embodiments, the inflow of air may cause theparticulate material 89 to fall toward the forming surface 24 in a morelinear path. For instance, as air enters the particulate materialdelivery chamber 60 a, the air may be pulled toward the forming surface24 by the vacuum pressure in the chamber 60 a, and may travel in agenerally linear manner. The air may pull the particulate material 89toward the forming surface 24, and the location of the particulatematerial 89 deposited at the forming surface 24 may be more heavilyinfluenced by individual starting positions of the particulate material89 at the inlet 61 a.

However, in still other additional or alternative embodiments, an upperregion of the particulate material delivery chamber 60 a may be sealedand may prevent air from entering the particulate material deliverychamber 60 a. In these embodiments, the air within the particulatematerial delivery chamber 60 a may be more turbulent than in theembodiments where the upper region of the particulate material deliverychamber 60 a allows entry of air, as represented by arrows 121. In theseembodiments, the relatively greater turbulence may cause the particulatematerial 89 to fall in much less linear paths and, therefore, thelocation of the particulate material 89 deposited at the forming surface24 may be less dependent on their initial starting position at the inlet61 a than where the upper region of the particulate material deliverychamber 60 a is open to the air. In at least some of these embodiments,the resulting formed absorbent cores may have a relatively more evendistribution of particulate material 89 throughout both thecross-machine direction 56 and the machine direction 54.

Although FIGS. 4A-B only depict particulate material delivery chamber 60a, it should be understood that particulate material delivery chamber 60b may be similar to the depicted particulate material delivery chamber60 a. However, it should also be understood that contemplatedembodiments of the present disclosure include apparatuses includingparticulate material delivery chambers 60 a, 60 b that differ from eachother. For instance, particulate material delivery chamber 60 a mayinclude a first set of features that were described above with respectto FIGS. 4A-B, while particulate material delivery chamber 60 b includesa second, different set of features. As one illustrative example,particulate material delivery chamber 60 a may include an inlet, e.g.inlet 61 a, that is oriented generally parallel with respect to ground94 and/or the base of the forming drum 87 while particulate materialdelivery chamber 60 b may include an inlet, e.g. inlet 61 b, that isoriented at an angle of 45 degrees with respect to ground 94 and/or thebase of the forming drum 87. Of course, this is just one example. Moregenerally, each of the particulate material delivery chambers 60 a, 60 bmay include any of the features described above with respect to FIGS.4A-B, and the specific set of features of each of particulate materialdelivery chambers 60 a, 60 b may not be the same.

FIG. 5 depicts pulpless absorbent cores 101 as they may appear whenexiting apparatus 20. In some examples, the absorbent cores 101 may beformed on a continuous carrier sheet, for instance the base carriersheet 70 as shown in FIG. 1. As the base carrier sheet 70 including thevarious adhesives and particulate material exit off of the forming drum26, another continuous carrier sheet, for instance the top carrier sheet75, may be applied over the top of the base carrier sheet 70. In thismanner, a continuous length of absorbent core may be formed by apparatus20. However, as mentioned previously, in some embodiments, the formingsurface 24 may include one or more masking members which may block aportion of the forming surface 24. In such embodiments, portions of theresulting length of the absorbent core may include gaps where there isno, or relatively little, particulate material content. These gaps arerepresented by gap regions 115 in FIG. 5. As the absorbent cores 101were being formed on the forming surface 24, the applied vacuum wouldhave been blocked by the masked portions of the forming surface suchthat little to no particulate material would have been drawn to the basecarrier sheet 70 in gap regions 115. Accordingly, in such embodiments,discrete absorbent cores 101 may be formed on the continuous basecarrier sheet 70, as shown in FIG. 5. The base carrier sheet 70 and thetop carrier sheet 75 may later be cut, for instance along cut lines 118,in order to form separated absorbent cores. In at least someembodiments, a knife roll may be used to cut the base carrier sheet 70and the top carrier sheet 75 into separated absorbent cores.

FIG. 6A depicts an example cross-section of an absorbent core 101 takenalong line A-A′ in FIG. 5. In the example of FIG. 6A, the absorbent core101 was formed using only two adhesives. For instance, the absorbentcore 101 of FIG. 6A includes the base carrier sheet 70. On top of thebase carrier sheet 70 is the first adhesive 120, represented by the‘x’s. The first adhesive 120, in some embodiments, may comprise andadhesive such as adhesive 78 described with respect to FIG. 1. Adhesive120 may have been applied to the base carrier sheet 70, for instance, inthe first adhesive application zone 80 of FIG. 1.

On top of the first adhesive 120 is the first amount of particulatematerial 122, represented by particulate material particles 89. Thefirst amount of particulate material 122 may have been applied to thefirst adhesive 120, for example, in the particulate material deliverychamber 60 a of FIG. 1. The first amount of particulate material 122 mayhave a thickness of between about 0.1 mm and about 1 mm.

On top of the first amount of particulate material 122 is the secondadhesive 124, represented by the ‘w’s. The second adhesive 124, in someembodiments, may comprise an adhesive such as adhesive 88 described withrespect to FIG. 1. The second adhesive 122 may have been applied to thefirst amount of particulate material 122, for instance, in the secondadhesive application zone 81 of FIG. 1.

On top of the second adhesive 124 is the second amount of particulatematerial 126. The second amount of particulate material 126 may havebeen formed, for example, in the particulate material delivery chamber60 b of FIG. 1. The second amount of particulate material 126 may have athickness of between about 0.1 mm and about 1 mm. Finally, the topcarrier sheet 75 is shown disposed on top of the second amount ofparticulate material 126.

In some embodiments, some of the adhesive 124 may penetrate into thefirst amount of particulate material 122. For instance, in the exampleof FIG. 6A, strands of the first adhesive 124 (as represented by the‘w’s) are shown penetrating the first amount particulate material 122 adistance 130. In some examples, distance 130 may range from betweenabout 0.1 mm to about 1 mm. Generally, where the adhesive 124 is a SAABadhesive, the distance 130 may be on the higher end of the range, asSAAB may be more effective at penetrating the first amount ofparticulate material 122 than other types of adhesives, such as hot-meltadhesive. The greater penetration distance of SAAB may allow forrelatively greater stabilization of the particulate material 89 thanother types of adhesive that have lesser penetrating ability.

FIG. 6B depicts an example cross-section of an alternative absorbentcore 101′ taken along line A-A′ in FIG. 5. In the example of FIG. 6B,the absorbent core 101′ was formed using three separate adhesiveapplications. For instance, the absorbent core 101′ of FIG. 6B may bethe same as the absorbent core 101 of FIG. 6A except that the absorbentcore 101′ of FIG. 6B further includes third adhesive 128, which is alsorepresented by ‘w’s. This is because in the embodiment of FIG. 6B, thesecond adhesive 124 and the third adhesive 128 are the same adhesive,such as a SAAB adhesive, but may have been applied in separate processsteps.

The third adhesive 128, in some embodiments, may comprise adhesive 98 aof FIG. 1. In these examples, the third adhesive 128 may have beenapplied to the second amount of particulate material 126 in the thirdadhesive application zone 91 a. As with the second adhesive 120, thethird adhesive 128 may penetrate at least partially into the particulatematerial 89. The penetration distance of the third adhesive 120 is shownby penetration distance 136, which may range from about 0.1 mm to about2 mm. In at least some embodiments, the third adhesive 128 may penetratethroughout the entire laminate structure of absorbent core 101′.

In other embodiments, however, the third adhesive 128 may not be thesame as the second adhesive 124. For instance, in at least somecontemplated embodiments, the third adhesive may be applied to the topcarrier sheet 75 rather than the second amount of particulate material126. In these embodiments, the third adhesive may be a hot-melt adhesiverather than a SAAB adhesive, as SAAB adhesives may not be suitable forapplication to carrier sheets. Accordingly, the third adhesive 128 maybe applied to the top carrier sheet such as in third adhesiveapplication zone 91 b of FIG. 1 instead of in third adhesive zone 91 a.

In general, as shown in FIGS. 6A and 6B, absorbent cores 101 and 101′may have overall thicknesses 123, 125, respectively. Some suitablevalues for thicknesses 123, 125 range from between about 0.2 mm to about2.0 mm. However, as will be described in more detail with respect toFIG. 8, the processes described herein may further include additionalapplications of adhesive and of particulate material, forming evenlarger laminate structures.

In even further additional or alternative embodiments, one or moretissue or other non-woven sheets may be interspersed between theadhesives and particulate material of the absorbent cores 101, 101′.With specific respect to FIG. 6A, for instance, in some embodiments anintermediate tissue or other non-woven material (not shown) may beplaced on top of the first amount of particulate material 122. Then, thesecond amount of particulate material 126 may be deposited onto thatintermediate tissue or other non-woven material. In further embodiments,an adhesive may then be applied to the laminate structure, as shown inFIG. 6B. Although only shown with two separate application ofparticulate material, as will be described in more detail with respectto FIG. 8, contemplated absorbent cores may include any suitable numberof applications of particulate material. Accordingly, in suchembodiments, an intermediate tissue or other non-woven sheet may bedisposed between each adjacent application of particulate material.

FIG. 7 depicts an alternative pulpless absorbent core forming apparatus200. Pulpless absorbent core forming apparatus 200 may generally besimilar to apparatus 20, except that instead of using a forming drum,pulpless absorbent core forming apparatus 200 uses a planer formingconveyer 226. Although the apparatus 200 may be slightly different fromthe apparatus 20, the method of forming pulpless absorbent cores withthe apparatus 200 is very similar to the process described with respectto apparatus 20. For instance, the base carrier sheet 270 is first fedonto the forming conveyer 226. The base carrier sheet 270 thenencounters adhesive application zone 281, where adhesive applicator 276applies adhesive 278 to the base carrier sheet 270.

Next, the base carrier sheet 270 may enter particulate material deliverychamber 260 a. Particulate material may be delivered to the particulatematerial delivery chamber 260 a from the hopper 290 through connectingpipe 268 and delivery pipe 264. Delivery pipe 264 may enter theparticulate material delivery chamber 260 a and form particulatematerial delivery conduit 262 a. The particulate material delivered tothe particulate material delivery conduit 262 a ultimately exits theparticulate material delivery conduit 262 a through inlet 261 a. In someembodiments, a metering device 292 may be present to meter out aspecific amount of particulate material from the hopper 290 to ensure apredetermined amount of particulate material flows to particulatematerial delivery conduit 262 a.

Additionally, in at least some of these embodiments, a vacuum chamber228 a may be present under the forming conveyer. For instance, theforming conveyer may have a foraminous forming surface (not shown) andair may be able to move across the foraminous forming surface. In theregion of vacuum chamber 228 a, air may be moving from within theparticulate material delivery chamber 260 a through the foraminousforming surface and into a duct (not shown) coming out of the formingconveyer 226. This movement of air may pull particulate material exitinginlet 261 a toward the forming conveyer to be deposited onto theadhesive 278 and the base carrier sheet 270 forming a layer comprising afirst particulate material. Although vacuum ducts 228 a and 228 b areshown only in the vicinity of the particulate material delivery chambers260 a, 260 b, in other embodiments, vacuum chambers 228 a, 228 b mayextend outside of the region around the particulate material deliverychambers 260 a, 260 b and over a greater extent of the forming conveyer226 than is shown in FIG. 7.

After exiting the particulate material delivery chamber 260 a, the basecarrier sheet 270, now including adhesive 278 and a first amount ofparticulate material, encounters adhesive application zone 281. Withinadhesive application zone 281, an adhesive applicator 286 appliesadhesive 288 onto the first amount of particulate material that wasdeposited onto adhesive 278 and the base carrier sheet 270 within theparticulate material delivery chamber 260 a.

The base carrier sheet 270 may then enter the particulate materialdelivery chamber 260 b. Particulate material may be delivered to theparticulate material delivery chamber 260 b through connecting pipe 268and through delivery pipe 266. Delivery pipe 266 may enter theparticulate material delivery chamber 260 b and form particulatematerial delivery conduit 262 b, which in turn may end at inlet 261 b.Particulate material delivered from the hopper 290 may exit inlet 261 band be drawn toward the adhesive 288 due to vacuum chamber 228 b.Ultimately, a second amount of particulate material may be depositedonto the adhesive 288.

Further processing steps may be included to ultimately form pulplessabsorbent cores 301. For instance, in some embodiments, a top carriersheet (not shown) may be applied over the second amount of particulatematerial. Additionally, a third adhesive zone 291 may be included whereadhesive applicator 296 applies a third adhesive, adhesive 298 onto thesecond amount of particulate material, or, alternatively, onto the topcarrier sheet before the top carrier sheet is applied to the secondamount of particulate material. In still further embodiments, theresulting pulpless absorbent cores may be further processed, for exampleby delivery through a nip roller, or separation by a knife roll.Generally, any of the additional or alternative process steps describedwith respect to apparatus 20 may also be implemented with respect toapparatus 200.

In further alternative embodiments, it should be understood that thepulpless absorbent cores contemplated by this disclosure are not limitedto only two particulate material applications. For instance, FIG. 8depicts a generic pulpless absorbent core 101″ that may be formedaccording to the techniques disclosed herein and having any suitablenumber of particulate material applications. The pulpless absorbent core101″ includes a base carrier sheet 140, a top carrier sheet 145, and afirst amount of particulate material 150 and a second amount ofparticulate material 151. The pulpless absorbent core 101″ furtherincludes a first adhesive 152 and a second adhesive 153. The adhesives152, 153 and the first and second amounts of particulate material 150,151 may be applied in a manner similar to that described with respect toapparatus 20 or 200.

However, pulpless absorbent core 101″ may be formed from any suitablenumber of additional adhesive and particulate material applications. Forinstance, each pair of an additional application of adhesive and anotheramount of particulate material may be thought as a unit building up theabsorbent core 101″. Accordingly, apparatus 20 or 200 may be modified toinclude additional adhesive application zone and particulate materialdelivery chamber units situated after second adhesive application zone81 and particulate material delivery chamber 60 b or adhesiveapplication zone 281 and particulate material delivery chamber 260 b.For each additional adhesive application zone and particulate materialdelivery chamber unit, pulpless absorbent core 101″ may include anotheradhesive and amount of particulate material. Although the pulplessabsorbent core 101″ is contemplated to include any number of suitableadditional units of adhesive and particulate material, as indicated bydots 156, some example suitable number of adhesive and particulatematerial units include 3, 4, 5, 6, and 7.

As mentioned previously, in some embodiments, one or more maskingmembers may be used in order to form shaped pulpless absorbent cores.FIG. 9 depicts forming drum 26 including example masking members 160,although similar masking members may be used with forming conveyer 226.Masking members 160 mask portions of the forming surface 24, creating apattern of shaped un-masked areas of the forming surface 24. Theseshaped un-masked areas will affect a distribution of particulatematerial within the resulting absorbent cores, thereby helping to createthe shaped absorbent cores.

Although only shown with one example shape in FIGS. 9 and 10, in othersuitable embodiments, the masking members 160 can have any number ofdifferent patterns. In still further embodiments, each of the maskingmembers 160 can have different patterns and may be arranged in any orderon the forming drum 26. The illustrated system of masking members 160 inFIG. 9 includes substantially identical masking members 160 arrangedconsecutively around the circumference of the forming drum 26. Themasking members 160 can be joined and assembled to the forming drum 26and/or the forming surface 24 by employing any conventional attaching ormounting mechanisms. For example, the masking members 160 may be securedto the forming surface 24 by a plurality of bolts inserted through holesin the masking members 160 and the forming surface 24.

The masking members 160 may have any shape suitable for mounting ontothe forming surface 24. For example, the masking members 160 may have anouter perimeter that forms a substantially rectangular shape.Additionally, the masking members 160 may have a slight curve alongtheir length in the machine direction 54 to form an arc for fitting onthe cylindrical forming surface 24. In other suitable embodiments, themasking members 160 may be substantially flat for fitting on planarforming surfaces, such as the planer forming conveyer 226 of apparatus200. The curve of each masking member 160 may have a radiussubstantially equal to the radius of the forming surface 24 such thatthe masking members 160 fit on the forming surface 24. When joinedtogether, a series of masking members 160 can completely concentricallyencircle the circumference of the forming surface 24.

FIG. 10 depicts a close-up of one exemplary masking member 160 disposedover the forming surface 24. As can be seen in FIG. 10, masking member160 includes both masking end portions 162 and masking side portions164. Masking side portions 164 may extend along the masking member 160for a distance 166. Some example values of distance 166 may range fromabout 10 cm to about 30 cm. Additionally, masking side portions 164 mayextend inward from the edges of the masking member 160 a distance 168.Some example values of distance 168 may range from about 1 cm to about 5cm. The masking side portions 164 may act to form a crotch region 170 inthe resulting formed absorbent cores.

When the masking members 160 are used within the processes describedwith respect to apparatus 20 and apparatus 200, the masking members 160may affect a distribution of particulate material within a resultingabsorbent core. As described previously, as the base carrier sheettravels around the forming drum 26, the base carrier sheet may be drawnto the forming surface 24 by the use of a vacuum drawing air throughforming surface 24 and into an interior of the forming drum 26.Additionally, as the base carrier sheet travels through a particulatematerial delivery chamber, the particulate material may be drawn to thebase carrier sheet by the vacuum. Where masking members 160 are used,the base carrier sheet travels around the forming drum 26 on top of themasking members 160, which effectively block air moving through theforming surface 24 in the masked areas. Accordingly, as the base carriersheet travels through a particulate material delivery chamber, theparticulate material will be drawn preferentially onto the base carriersheet over the un-masked areas of the forming surface 24.

FIG. 11 depicts example shaped absorbent cores 201 that may be formedusing the masking members 160. In the example of FIG. 11, differentregions of the shaped absorbent cores 201 are shown with dashed lines.The shaped absorbent cores 201 may include regions of relatively higheraverage basis weights, such as within the crotch regions 170 and otherregions where the forming surface 24 was un-covered by the maskingmembers 160. The shaped absorbent cores 201 may also include regions ofrelatively lower average basis weights, such as in end regions 171 andleg regions 173. In embodiments contemplated by this disclosure, theareas of relatively higher average basis weights may have average basisweights ranging from between about 100 grams per meter (gsm) to about1000 gsm. The areas of relatively lower average basis weights may haveaverage basis weights ranging from between about 50 gsm to about 400gsm. In some embodiments, the shaped absorbent cores 201 may beseparated into individual shaped absorbent cores by cutting the lengthof resulting shaped absorbent cores 201 in the end regions 171.

The shaped absorbent cores 201 formed using masking members, such asmasking members 160, may have some benefits over non-shaped absorbentcores. For instance, the regions of lower basis weights of particulatematerial may allow the shaped absorbent cores 201 to have a loweroverall particulate material content than non-shaped cores, resulting inlower manufacturing costs. However, because of the locations of theareas of higher basis weights, overall absorption performance of theshaped absorbent cores 201 may be at least the same as correspondingnon-shaped absorbent cores.

As mentioned previously, the pulpless absorbent cores of the presentdisclosure may be truly pulpless, or the pulpless absorbent cores mayhave a relatively small pulp content. For example, some of the pulplessabsorbent cores of the present disclosure may include an amount ofcellulose fibers that is between about 0.5% and about 10%, by weight, ofthe total contents of the cores. The addition of a small amount ofcellulose fibers to the absorbent cores the present disclosure mayimpart a greater feeling of softness or provide other beneficialproperties to the absorbent cores. FIG. 12 depicts one exampleapparatus, apparatus 300, which may be used to form the pulplessabsorbent cores that have a small pulp content.

Apparatus 300 is very similar to apparatus 20 of FIG. 1. For instance, abase carrier sheet 370 may be fed onto forming drum 326. The basecarrier sheet 370 may then advance through a series of adhesiveapplications zone 380, 381 (and, possibly 391 a or 391 b) andparticulate material delivery chambers 360 a, 360 b. A top carrier sheet375 may then be applied to form the resulting absorbent cores 399.

One difference between apparatus 20 and apparatus 300 is that apparatus300 may further include fiberizer 340. In the embodiment of FIG. 12, thefiberizer 340 may be fed pulp or cellulose sheets and break up thecellulose sheets into many individual fibers. The fiberizer 340 may be ahammer mill-type fiberizer, or any other suitable type of fiberizerknown in the art. The cellulose fibers may exit the fiberizer 340 intodelivery ducts 341 and 342. The delivery ducts may ultimately formmaterial delivery chambers 360 a, 360 b.

The material delivery chambers 360 a, 360 b may differ from theparticulate material delivery chambers 60 a, 60 b of apparatus 20 inthat the material delivery chambers 360 a, 360 b may deliver bothparticulate material and cellulose fibers to the base carrier sheet. Forexample, cellulose fibers may travel through the delivery ducts 341, 342and enter the material delivery chambers 360 a, 360 b. Gravity, alongwith the vacuum pressure within the material delivery chambers 360 a,360 b will cause the cellulose fibers to deposit onto the base carriersheet 370.

Particulate material may also be delivered to the material deliverychambers 360 a, 360 b. For instance, particulate material may be storedin hopper 390 and may be delivered to the material delivery chambers 360a, 360 b through delivery pipes 364, 366. The delivery pipes 364, 366may ultimately form particulate material delivery conduits 362 a, 362 bwithin the material delivery chambers 360 a, 360 b. The deliveredparticulate material may exit the particulate material delivery conduits362 a, 362 b within the material delivery chambers 360 a, 360 b. Similarto the pulp fibers, gravity and the vacuum pressure within the materialdelivery chambers 360 a, 360 b will cause the particulate material to bedeposited onto the base carrier sheet 370. In this manner, apparatus 300may be used to form pulpless absorbent cores containing an amount ofcellulose fibers representing between about 0.5% and about 10% of thetotal weight of the materials within the pulpless absorbent cores.

FIG. 13 depicts a cross-section of an example absorbent core 399 thatmay be formed by the apparatus 300. FIG. 13 depicts absorbent core 399including base carrier sheet 370 and top carrier sheet 375. Absorbentcore 399 also includes adhesives 378 and 388, represented by ‘x’s and‘w’s, respectively. In general, the absorbent core 399 may be similarto, and may be formed similarly to, the other absorbent cores of thepresent disclosure, such as absorbent cores 101, 101′, and 101″. Unlikethe previous absorbent cores, however, absorbent core 399 furtherincludes cellulose fibers 393 a, 393 b. As can be seen, cellulose fibers393, 393 b are disposed intermixed with the individual particulatematerial particles 389. Cellulose fibers 393 a may be deposited, forinstance, along with a first amount of particulate material particles389, such as in particulate material delivery chamber 360 a of FIG. 12.Cellulose fibers 393 b may be deposited, for instance, along with asecond amount of particulate material particles 389, such as inparticulate material delivery chamber 360 b of FIG. 12. As mentionedpreviously the addition of cellulose fibers may impart a greatersoftness to absorbent cores of the present disclosure, and the cellulosefibers may further help to stabilize the particulate material particles389 between the base carrier sheet 370 and the top carrier sheet 375.

Again, it should be understood that FIG. 12 only represents onecontemplated embodiment. In further embodiments, apparatuses 20 and/or200 may be modified to include only a single particulate materialdelivery chamber that further intermixes cellulose fibers with theparticulate material before deposition at a forming surface, instead ofthe two shown with respect to FIG. 12. In general, the apparatuses 20and/or 200 may include a number of particulate material deliverychambers that allow for the intermixing of cellulose fibers andparticulate material that is less than all of the particulate materialdelivery chambers of the apparatuses. In these alternative embodiments,then, a relatively smaller proportion of the formed absorbent cores mayinclude cellulose fibers. For instance, if the cellulose fibers wereintermixed with a first amount of particulate material, the mixture ofcellulose fibers and particulate material may be located proximate thebase carrier sheet. However, if the cellulose fibers were intermixedwith a second (or third, fourth, etc.) amount of particulate material,the mixture of cellulose fibers and particulate material may be locatedcloser to the top carrier sheet than the first amount of particulatematerial.

In alternative embodiments, instead of forming the pulpless absorbentcores of the present disclosure with both a base carrier sheet and a topcarrier sheet, as described previously, some contemplated methods mayonly use a single carrier sheet. FIGS. 14A and 14B depict exampleembodiments where a single carrier sheet may be used instead of both abase carrier sheet and a top carrier sheet.

FIG. 14A depicts carrier sheet 405. In some embodiments, carrier sheet405 may have a first edge region 402 having a first edge 403 and asecond edge region 406 having a second edge 407, with a middle region404 disposed between the first edge region 402 and the second edgeregion 406. In the embodiment of FIG. 14A, particulate material andadhesive may only be applied within the middle region 404. Afterapplication of adhesive and particulate material, instead of applying asecond carrier sheet as described herein previously, the second edgeregion 406 may be folded over the middle region 404 and onto the firstedge region 402 such that the second edge 407 is disposed proximate thefirst edge 403. The edges 403, 407 may then be bonded together to createan enclosed pulpless absorbent core. Bonding the edges 403 and 407together may be done by any suitable method, such as by pressurebonding, adhesive bonding, ultrasonic bonding, or the like. Theapparatuses described herein may be modified to produce such pulplessabsorbent cores. For instance, instead of machinery to apply the topcarrier sheets, the apparatuses described herein may include folding andbonding machinery, which are well known in the art, to fold the secondedge region 406 onto the first edge region 402 and to bond the regions402, 406 together.

In some embodiments according to FIG. 14A, the carrier sheet 405 mayhave a width 410. Width 410 may be greater than twice the width of aforming surface used to create pulpless absorbent cores, oralternatively greater than twice the width of an un-masked portion of aforming surface used to create pulpless absorbent cores. In somespecific examples, width 410 may range between about 25 cm and about 60cm.

The middle region 404 may have a width 412. The width 412 may range frombetween about 40% to about 50% of the overall width 410 of the carriersheet 405. Additionally, the first edge region 402 may have a width 414that is be between about 0.5% and about 10% of the overall width 410 ofthe carrier sheet 405.

FIG. 14B depicts another example embodiment of a single carrier sheetthat may be used to form the pulpless absorbent cores of the presentdisclosure. In the example of FIG. 14B, the carrier sheet 450 may havean overall width 460. The overall width 460 may have values similar tothose described with respect to width 410. Additionally, the carriersheet 450 may have a first edge region 452, a middle region 454, and asecond edge region 456. As with the embodiment of FIG. 14A, adhesive andparticulate material may only be applied to the carrier sheet 450 withinthe middle region 454. After application of adhesive and particulatematerial to the middle region 454, one of the first edge region 452 orthe second edge region 456 may be folded over onto the middle region454. Then, the other of the first edge region 452 or the second edgeregion 456 may be folded over the middle region 454. In someembodiments, the edge regions 452, 456 may overlap over the middleregion 454, and at least a portion of each of the first edge region 452and the second edge region 456 may be bonded together to form anenclosed pulpless absorbent core.

Similarly to carrier sheet 405, in some embodiments the width 460 of thecarrier sheet 450 may be greater than twice the width of a formingsurface used to create pulpless absorbent cores, or greater than anun-masked portion of a forming surface used to create pulpless absorbentcores. However, this is not necessary in all embodiments. In at leastsome embodiments, width 460 may range between about 25 cm and about 60cm.

The region 454 of the carrier sheet 450 may have a width 462. The width462 may range from between about 33% to about 50% of the overall width460 of the carrier sheet 450. In some embodiments, each of the firstedge region 452 and the second edge region 456 may have a width (notshown) that is between about 25% and about 33% of the overall width 460.However, the widths of the first edge region 452 and the second edgeregion 456 do not necessarily need to be equal. For example, the widthof the first edge region 452 may be between about 35% and about 40% ofthe overall width 460 and the width of the second edge region 456 may bebetween about 10% and about 25% of the overall width of 460, or viceversa.

In at least some alternative embodiments, instead of depositingparticulate material and adhesive in discrete steps, the apparatusesdisclosed herein may be modified to deposit one or more matrix layers,with each matrix layer comprising a combination of particulate materialand adhesive. For instance, FIGS. 15A and 15B depict top-down exemplaryschematics of machinery that may be used with the various apparatusesdescribed herein to form a matrix layer within an absorbent core.

FIG. 15A depicts exemplary forming drum 526. The forming surface 524 isdepicted disposed on the forming drum 526 extending between the drumrims 552. Particulate material delivery conduit 562 is also shown inFIG. 15A. FIG. 15A further depicts adhesive application nozzles 510 andair blowers 511. In some embodiments, the particulate material deliveryconduit 562 and the adhesive application nozzles 510 may be disposedwithin an overall chamber (not shown in FIG. 15A), for example aparticulate material delivery chamber as described herein, but this isnot necessary in all embodiments.

As shown in FIG. 15A, the particulate material delivery conduit 562 cangenerally extend for a length in a machine direction 554 that is greaterthan a width that the particulate material delivery conduit 562 extendsin a cross-machine direction 556. Additionally, the particulate materialdelivery conduit 562 may generally be disposed over a center region ofthe forming surface 524. Some example lengths for the particulatematerial delivery conduit 562 range from between about 10 cm to about100 cm. Some example widths for the particulate material deliveryconduit 562 range from between about 15 cm to about 50 cm.

Disposed adjacent to the particulate material delivery conduit 562 areone or more adhesive application nozzles 510. The adhesive applicationnozzles 510 may be configured to deliver adhesive into particulatematerial as the particulate material falls from the particulate materialdelivery conduit 562 toward the forming surface 524. When particulatematerial is delivered from the particulate material delivery conduit562, and adhesive delivered from the adhesive application nozzles 510,the particulate material and the adhesive intermix as they fall towardthe forming surface 524. As the particulate material and the adhesiveare deposited at the forming surface 524, the particulate material andthe adhesive form a matrix of particulate material and adhesive, asdescribed in more detail below.

In some embodiments, the adhesive application nozzles 510 may beconfigured to provide a generally continuous stream of adhesive, whilein other embodiments one or more of the adhesive application nozzles 510may be configured to alternatingly be turned “on” and “off” to providediscontinuous streams of adhesive through one or more of the adhesiveapplication nozzles 510. Although depicted as five separate adhesiveapplication nozzles 510, in other embodiments, additional or feweradhesive application nozzles 510 may be used. In different embodiments,the number of adhesive application nozzles 510 may range from betweenabout five to about twenty.

Air blowers 511 are optional components and, where present, maygenerally be disposed on either side of the particulate materialdelivery conduit 562/adhesive application nozzles 510, or on both sidesas shown in FIG. 15A. In the example of FIG. 15A, the air blowers 511may be disposed a distance 512 from the particulate material deliveryconduit 562 and a distance 514 from the adhesive application nozzles510. The distance 512 may range between about 1 cm and about 10 cm. Thedistance 514 may range between about 3 cm and about 8 cm.

Where present, the air blowers 511 may deliver air jets at predeterminedvelocities, sufficient to urge the adhesive streams from at least someof the adhesive application nozzles 510 inward and toward the center ofthe substrate the forming surface 524, either continuously or forperiodic intervals. The periodic intervals may be effected byperiodically switching one or more of the air blowers 511 “on” and“off,” by periodically blocking or diverting the jets of air from theair blowers 511 so that the jets of air do not manipulate the adhesivestreams and/or particulate material, or by reducing the force of thejets of air to manipulate the adhesive streams and/or particulatematerial to a lesser extent. In this manner, the use of the air blowers511 may allow for shaping of the adhesive and/or particulate material,particularly influencing the extent to which the adhesive and/orparticulate material is deposited at the forming surface 524 in thecross-machine direction 556. The air blowers 511 may help to cominglethe particulate material and the adhesive as they are delivered from theparticulate material delivery conduit 562 and the adhesive applicationnozzles 510, respectively, as the particulate material and the adhesivefall toward the forming surface 524. The air blowers 511 may have anopening diameter of about 0.5-5 mm, suitably about 1-3 mm, depending onthe size of absorbent core being formed, line speed, number of airnozzles, air pressure, adhesive basis weight, and other processvariables.

FIG. 15B depicts another exemplary absorbent material delivery chamber560′ disposed over forming drum 526′. The forming surface 524′ isdepicted disposed on the forming drum 526′ extending between the drumrims 552′. In general, the embodiment shown in FIG. 15B may be similarto the embodiment shown in FIG. 15A. However, in the embodiment of FIG.15B, the orientation of the particulate material delivery conduit 562′and the adhesive application nozzles 510′ may be skewed with respect tothe machine direction 554′. For example the particulate materialdelivery conduit 562′ and the adhesive application nozzles 510′ may beoriented at an angle 520 with respect to the machine direction 556′. Theangle 520 may range from between one degree to ninety degrees.

In general, the angle 520 may be chosen in order to influence across-machine direction 554′ spread of the deposited particulatematerial from the particulate material delivery conduit 562′ and theadhesive from the adhesive application nozzles 510′. As can be seen inFIG. 15B, with the particulate material delivery conduit 562′ and theadhesive application nozzles 510′ oriented at the angle 520, thecross-machine direction 556′ spread of the deposited particulatematerial and the adhesive may be greater than the cross-machinedirection 556 spread of the deposited particulate material and theadhesive in FIG. 15A because the particulate material delivery conduit562′ and the adhesive application nozzles 510′ span an initially greatercross-machine direction 556′ distance than the distance the particulatematerial delivery conduit 562 and the adhesive application nozzles 510span in the cross-machine direction 556.

In general, the components described above with respect to FIGS. 15A and15B may be incorporated into any of the processes described with respectto apparatuses 20, 200, or 300. The components may be used in place ofeither of the first particulate material delivery chamber in any of thedescribed processes or any subsequent particulate material deliverychamber. In this manner, the matrix of particulate material and adhesiveformed by use of the components of FIG. 15A or 15B may be either formedon a base carrier sheet or on any prior application of particulatematerial or adhesive. In at least some embodiments, the disclosedapparatuses may comprise two or more instances of the components ofFIGS. 15A and/or 15B to form absorbent cores that have two or morematrices, or a thicker region, of particulate material and adhesivedisposed within an absorbent core.

The spread of the deposited matrix of particulate material and adhesivein the cross-machine direction 556 within formed absorbent cores maygenerally be less than the spread of other non-matrix applications ofparticulate material and adhesive of the absorbent cores. For instance,where the matrix of particulate material and adhesive is a deposited asa second application, the first application of particulate material(again, which may not be part of a matrix with adhesive) may span amajority of a cross-machine direction 556 width of the formed absorbentcore. The matrix of particulate material and adhesive, however, may spanin the cross-machine direction 556 less than the first application ofparticulate material. This may allow targeting of particulate materialto areas of the absorbent core that will be most beneficial forabsorption, e.g. where the particulate material in the matrix ofparticulate material and adhesive is only present in particular regionsof the absorbent core. This may further allow for the overallparticulate material content of the formed absorbent core to be lessthan if the matrix of particulate material and adhesive spanned thewhole cross-machine direction 556 width of the absorbent core, or atleast to the same extent as the first application of particulatematerial.

FIG. 16 depicts a side view of the components described in FIGS. 15A and15B. As can be seen in FIG. 16, adhesive 530 may exit adhesiveapplication nozzles 510 and particulate material 532 may exit theparticulate material delivery conduit 562 above air streams 534 createdby air blowers 511 a, 511 b. As the particulate material 532 and theadhesive 530 travel toward the forming surface 524, the particulatematerial 534 and the adhesive 530 become entrained in air streams 534and become comingled in region 535 above the forming surface 524. Thiscan be seen in FIG. 16 as the adhesive 530 is intermixed with theparticulate material 532 in the region 535 before being deposited at theforming surface 524 as a matrix of particulate material 532 and adhesive530. Generally, the matrix of particulate material 532 and adhesive 530deposited at the forming surface 524 may span in the cross-machinedirection 556 a width 531. Again, it should be understood that airblowers 511 a, 511 b are option components. In embodiments where airblowers 511 a, 511 b are not present, the particulate material 532 andadhesive 530 may still intermix as they fall toward the forming surface524. For instance, vacuum pressure may draw the particulate material 532and adhesive 530 toward the forming surface 524 and cause theparticulate material 532 and adhesive 530 to intermix.

In some embodiments, the rate of revolution of the forming drum 526 inthe machine direction 554, the weight and volume of the particulatematerial 532 exiting the particulate material delivery conduit 562, theweight and volume of the adhesive 530 exiting the adhesive applicationnozzles 510, the strength of the air streams 534 from the air blowers511 a, 511 b, and other process factors may be modified to create awidth 531 that may be between about 5 cm and about 15 cm. In someembodiments, the strength of the vacuum within the forming drum 526 mayalso influence the width 531. For example, a stronger vacuum within theforming drum 526 may influence the particulate material 532 and theadhesive 530 as they fall toward the forming surface 524 and cause theparticulate material 532 and the adhesive 530 to spread more in thecross-machine direction 556 than in comparison to a weaker vacuum withinthe forming drum 526.

Air blowers 511 a, 511 b may additionally include nozzles 513 a, 513 bthat direct the streams of air 534 toward the particulate material 532and the adhesive 530. In at least some embodiments, the nozzles 513 a,513 b may be angled toward the forming surface 524 at an angle 533. Theangle 533 may range between about zero degrees to about sixty degrees.

FIG. 17 depicts a length of formed absorbent cores 570 comprisingconnected, individual absorbent cores 571 a-c that may be formed usingany of the processes described herein and further including a matrix ofparticulate material and adhesive formed by the processes described withrespect to FIGS. 15A, 15B, and 16. The connected, individual absorbentcores 571 a-c may later be separated forming discrete individualabsorbent cores, for example by cutting along cut lines 575.

The formed absorbent cores 571 a-c may have an overall core width 595and may include a center region 580 having a center width 590. Theabsorbent cores 571 a-c may further include a first edge region 581having a first edge region width 591 and a second edge region 582 havinga second edge region width 592. In some embodiments, the center width590 may generally correspond to the cross-machine direction 556 spreadof the matrix region of particulate material and adhesive of theabsorbent cores 571 a-c. In these embodiments, the center width 590 mayrange between about one-quarter to about three-quarters of the overallcore width 595. Accordingly, the cross-machine direction 556 spread ofthe matrix of particulate material and adhesive of the absorbent cores571 a-c may range between about one-quarter to about three-quarters ofthe overall core width 595. More generally, the center region 580 maycorrespond to a crotch region of the absorbent core 571 a-c. Forinstance, in some embodiments, the absorbent cores 571 a-c may beshaped, for instance as described with respect to FIGS. 10 and 11. Inthese embodiments, the center width 590 of the center region 580 maycorrespond to the width of the crotch region of these shaped absorbentcores. This may help to ensure that additional particulate material islocated at positions of the absorbent cores where the additionalparticulate material is able to be most effective, while also ensuringthat additional particulate material is not added to locations where theparticulate material is not needed or would be less effective, thushelping to keep manufacturing costs down.

In these embodiments, then, the first edge region width 591 and thesecond edge region width 592 may range between about three-eighths andabout one-eighth of the overall core width 595. In some specificexamples, the overall core width 595 may be between about 3 cm and about25 cm. In these examples, the center width 590 may range between about0.75 cm and about 18.75 cm, or more generally between about 1 cm andabout 20 cm. The first edge region width 591 and the second edge regionwidth 592, then, may range generally between about 1 cm and about 10 cm.

Another feature of the absorbent cores 571 a-c is that since the matrixof particulate material and adhesive spans only a portion of the overallcore width 595, the different regions of the absorbent cores 571 a-c mayhave different amounts of particulate material. For instance, in someembodiments, at least 25% of the total amount of particulate absorbentmaterial in one of the absorbent cores 571 a-c may be located within thecenter region 580. In other embodiments, at least 50% of the totalamount of particulate material in one of the absorbent cores 571 a-c maybe located within the center region 580. In still further embodiments,at least 75% of the total amount of particulate material in one of theabsorbent cores 571 a-c may be located within the center region 580.These values may translate into particulate material and adhesive basisweights of between about 100 gsm and about 1000 gsm. Accordingly, thebasis weights of the particulate material and adhesive located withinthe first edge region width 591 and the second edge region width 592 mayrange between about 50 gsm and about 400 gsm. These values may span auseful range for different absorbent articles where the cores 571 a-cmay be ultimately used.

FIGS. 18 and 19 depict cross-sections of exemplary absorbent cores 600and 601 that may represent a cross-section of the absorbent core 571 btaken along line B-B′ in FIG. 17. In the example of FIG. 18, theabsorbent core 600 may comprise a base carrier sheet 587. In at leastsome embodiments, a first adhesive 584, represented by the ‘x’s, may bedisposed directly on the base carrier sheet 587. Absorbent core 600further includes a first amount of particulate material 593 a applieddirectly to the first adhesive 584 (or directly to the base carriersheet 587 in embodiments that do not include the first adhesive 584disposed directly on the base carrier sheet 587) forming region 596.

Although not necessary in all embodiments, absorbent core 600 mayfurther include a second adhesive 583, as represented by the ‘w’s. Inthese embodiments, the second adhesive 583 may be applied onto the firstamount of particulate material 593 a that formed region 596. In at leastsome embodiments, the second adhesive 583 may comprise a sprayapplication aqueous binder (SAAB) adhesive. In these examples, as shownin FIG. 18, the second adhesive 583 may penetrate into the particulatematerial 593 a within region 596. Again, it should be understood thatthe second adhesive 583 may be applied only in some contemplatedembodiments.

Whether a second adhesive 583 is present or not, a matrix of particulatematerial and adhesive 585 may be disposed adjacent to the first amountparticulate material 593 a that forms regions 596. The matrix ofparticulate material and adhesive 585 may generally comprise a secondamount of particulate material 593 b and adhesive fibers 586. Theadhesive fibers 586 may be formed, for example, by adhesive applicationnozzles 510 described above with respect to FIGS. 15A, 15B, and 16. Thematrix of particulate material and adhesive 585 may be generallydisposed within region 597.

The matrix of particulate material and adhesive 585 forming region 596may comprise particulate material and adhesive having a basis weightranging between about 100 gsm to about 500 gsm. Additionally as can beseen, the matrix of particulate material and adhesive 585 may generallyspan throughout the center region 580, whereas the first amount ofparticulate material 593 a may span throughout the whole width of theabsorbent core 600, including throughout the first edge region 581 andthe second edge region 582. Due to this fact, the center region 580 maygenerally have a higher basis weight, of both particulate material andadhesive, than either of the first edge region 581 and the second edgeregion 582.

Although not shown explicitly in FIG. 18, in at least some embodiments,the absorbent core 600 may additionally include a third adhesivedisposed between the top carrier sheet 588 and matrix of particulatematerial and adhesive 585. The third adhesive may either may applieddirectly to the matrix of particulate material and adhesive 585 or maybe applied directly to the top carrier sheet 588, in accordance withpreviously disclosed techniques.

Finally, a top carrier sheet 588 may be applied to the matrix ofparticulate material and adhesive 585 resulting in the top carrier sheet588 being disposed directly on the matrix of particulate material andadhesive 585 or on the third adhesive. Additionally, as describedpreviously, in some embodiments, the top carrier sheet 588 may be thebottom carrier sheet 587 folded onto the matrix of particulate materialand adhesive 585 or the third adhesive to form the top carrier sheet588.

FIG. 19 depicts exemplary absorbent core 601. Exemplary absorbent core601 may comprise a base carrier sheet 587′. In at least someembodiments, a matrix of particulate material and adhesive 585′ may thenbe disposed directly on the base carrier sheet 587′. Alternatively inother embodiments, a first adhesive 584′ may be disposed directly on thebase carrier sheet 587′ and the matrix layer 585′ may then be disposeddirectly on the first adhesive layer 584′. In either case, as can beseen in FIG. 19, the matrix of particulate material and adhesive 585′may only span across a portion of the absorbent core 601. For instance,the matrix of particulate material and adhesive 585′ may only spanacross the center portion 580 of the absorbent core 601. The matrix ofparticulate material and adhesive 585′ may comprise both particulatematerial 593 b′ and adhesive fibers 586′. As can be seen, particulatematerial 593 b′ and the adhesive fibers 586′ are intermixed to form thematrix of particulate material and adhesive 585′. Additionally, thematrix of particulate material and adhesive 585′ may compriseparticulate material and adhesive having a basis weight between about100 gsm to about 500 gsm.

The absorbent core 601 may further comprise other particulate material,e.g. particulate material 593 a′, that is not part of a matrix ofparticulate material and adhesive fibers. The other particulate material593 a′ may have been applied to the absorbent core 601 after the matrixof particulate material and adhesive 585′ had been applied to theabsorbent core. The other particulate material 593 a′ may further beapplied to the absorbent core 601 throughout the entire width of theabsorbent core 601. Accordingly, as can be seen in FIG. 19, the otherparticulate material 593 a′ may span throughout all of regions 580-582,whereas the matrix of particulate material and adhesive 585′ may onlyspan throughout the center region 580. This may then result in thecenter portion 580 of the absorbent core 601 having a higher basisweight, both in terms of particulate material 592 a′ and 593 b′ andadhesive, than either of the first edge region 581 and the second edgeregion 582.

In some embodiments, a second adhesive 583′ may be disposed on the otherparticulate material 593 a′. For instance, the second adhesive 583′ maybe applied directly to the other particulate material 593 a′. As shownin FIG. 19, the second adhesive 583′ may be a spray application aqueousbinder (SAAB) adhesive, and the second adhesive 583′ may penetratethroughout the other particulate material 593 a′. Although not shown inFIG. 19, in some instances, the second adhesive 583′ may furtherpenetrate the matrix of particulate material and adhesive 585′. However,in other embodiments, the second adhesive 583′ may not be a SAABadhesive. For example, the second adhesive 583′ may be a hot-melt orother suitable adhesive. In these instances, the second adhesive 583′may be applied directly to the other particulate material 593 a′ and maynot appreciably penetrate the other particulate material 593 a′, or thesecond adhesive 583′ may be applied to the top carrier sheet 588′ beforethe top carrier sheet 588′ is applied to the other particulate material593 a′. In still further embodiments, the second adhesive 583′ may be aSAAB adhesive, and the absorbent core 601 may additionally comprise athird adhesive that is a hot-melt adhesive disposed between the otherparticulate material 593 a′ and the top carrier sheet 588′. Accordingly,whether applied directly to the other particulate material 593 a′ or thetop carrier sheet 588′, the second adhesive 583′ may be disposedgenerally between the other particulate material 593 a′ and the topcarrier sheet 588′.

Finally, a top carrier sheet 588′ is shown disposed adjacent to theother particulate material 593 a′. Again, depending on the specificembodiment, the top carrier sheet 588′ may be disposed directly on theother particulate material 593 a′ or there may be an adhesive disposedbetween the other particulate material 593 a′ and the top carrier sheet588′. Additionally, as described previously, in some embodiments, thetop carrier sheet 588′ may be the bottom carrier sheet 587′ folded ontothe first particulate absorbent material layer 593′ or the thirdadhesive layer 586′ to form the top carrier sheet 588′.

The pulpless absorbent cores the present disclosure may be used in manydifferent absorbent articles. For example, pulpless absorbent cores thepresent disclosure may be used in diapers and/or training pants in orderto help absorb urine and other liquid discharge from babies andtoddlers. The pulpless absorbent cores the present disclosure mayadditionally, or alternatively, be used in incontinence products,disposable underwear, and/or medical garments to help absorb liquiddischarge from people who may not be able to control their ability tourinate or defecate. Even further, the pulpless absorbent cores thepresent disclosure may additionally, or alternatively, be used infeminine care articles to help absorb vaginal discharges. These are justsome example absorbent articles in which the pulpless absorbent coresthe present disclosure may be used. In general, the pulpless absorbentcores the present disclosure may be used in any suitable absorbentarticle application.

As various changes could be made in the above without departing from thescope of the invention, it is intended that all matter contained in theabove description and shown in the accompanying drawings shall beinterpreted as illustrative and not in a limiting sense.

We claim:
 1. A method of forming an absorbent core, the methodcomprising: moving a foraminous forming surface in a machine direction;creating a pressure differential across the foraminous forming surface;advancing a base carrier sheet on the foraminous forming surface in themachine direction; applying a first adhesive and a first quantity ofsuperabsorbent material onto the base carrier sheet; and depositing amatrix of adhesive and superabsorbent material directly onto the firstadhesive and the first quantity of superabsorbent material, the matrixof adhesive and superabsorbent material comprising a second quantity ofsuperabsorbent material and a second adhesive, the second quantity ofsuperabsorbent material being dispensed from a superabsorbent materialdelivery conduit and the second adhesive comprising a fibrous adhesivedispensed from one or more application nozzles, the application nozzleslocated adjacent to the superabsorbent material delivery conduit atleast partially in the machine direction and wherein the fibrous secondadhesive and the second quantity of superabsorbent material mix prior todeposition onto the first adhesive and the first quantity ofsuperabsorbent material.
 2. The method of claim 1, wherein applying afirst adhesive and a first quantity of superabsorbent material onto thebase carrier sheet comprising depositing a matrix of the first adhesiveand the first quantity of superabsorbent material onto the base carriersheet, the first quantity of superabsorbent material being dispensedfrom a superabsorbent material delivery conduit and the first adhesivecomprising a fibrous adhesive dispensed from one or more applicationnozzles, the application nozzles located adjacent to the superabsorbentmaterial delivery conduit at least partially in a machine direction andwherein the fibrous first adhesive and the first quantity ofsuperabsorbent material mix prior to deposition onto the base carriersheet.
 3. The method of claim 1, further comprising adhesive to the basecarrier sheet prior to applying the first adhesive and the firstquantity of superabsorbent material.
 4. The method of claim 1, whereinthe superabsorbent material delivery conduit and the one or moreapplication nozzles dispensing the second adhesive are disposed within asuperabsorbent material delivery chamber.
 5. The method of claim 2,wherein the superabsorbent material delivery conduit and the one or moreapplication nozzles dispensing the first adhesive are disposed within asuperabsorbent material delivery chamber.
 6. The method of claim 1,wherein the first quantity of superabsorbent material is applied ontothe base carrier sheet to have a first cross-machine direction maximumwidth, the second quantity of superabsorbent material is applied to thefirst adhesive and the first quantity of superabsorbent material to havea second cross-machine direction maximum width, and wherein the secondcross-machine direction maximum width is different than the firstcross-machine direction maximum width.
 7. The method of claim 6, whereinthe first quantity of superabsorbent material is applied onto the basecarrier sheet to have a plurality of cross-machine direction widths, andwherein the second cross-machine direction maximum width is less than orequal to a minimum cross-machine direction width of the applied firstquantity of superabsorbent material.
 8. The method of claim 6, whereinthe second quantity of superabsorbent material is applied to the firstadhesive and the first quantity of superabsorbent material to have aplurality of cross-machine direction widths.
 9. The method of claim 1,wherein the superabsorbent material is gravity fed through thesuperabsorbent material delivery conduit.
 10. A method of forming anabsorbent core, the method comprising: moving a foraminous formingsurface in a machine direction; creating a pressure differential acrossthe foraminous forming surface; advancing a base carrier sheet on theforaminous forming surface in the machine direction; depositing a matrixof a first adhesive and a first quantity of superabsorbent material ontothe base carrier sheet, the first quantity of superabsorbent materialbeing dispensed from a first superabsorbent material delivery conduitand the first adhesive comprising a fibrous adhesive dispensed from oneor more first application nozzles with the fibrous first adhesive andthe first quantity of superabsorbent material mixing prior to depositiononto the base carrier sheet, the first application nozzles locatedadjacent to the first superabsorbent material delivery conduit at leastpartially in the machine direction; and depositing a matrix of a secondadhesive and a second quantity of superabsorbent material directly ontothe matrix of the first adhesive and the first quantity ofsuperabsorbent material, the second quantity of superabsorbent materialbeing dispensed from a second superabsorbent material delivery conduitand the second adhesive comprising a fibrous adhesive dispensed from oneor more second application nozzles with the fibrous second adhesive andthe second quantity of superabsorbent material mixing prior todeposition onto the first adhesive and the first quantity ofsuperabsorbent material, the second application nozzles located adjacentto the second superabsorbent material delivery conduit at leastpartially in a machine direction; and directing air from one or more airblowers in a direction toward the first superabsorbent material deliveryconduit.
 11. The method of claim 10, further comprising directing airfrom one or more air blowers in a direction toward the secondsuperabsorbent material delivery conduit.
 12. The method of claim 10,wherein the one or more air blowers are disposed adjacent, in across-machine direction, to the one or more first application nozzlesdispensing the fibrous first adhesive.
 13. The method of claim 11,wherein the one or more air blowers directing air toward the secondsuperabsorbent material delivery conduit are disposed adjacent, in across-machine direction, to the one or more second application nozzlesdispensing the fibrous second adhesive.
 14. The method of claim 10,wherein the one or more air blowers direct air toward the firstsuperabsorbent material delivery conduit in opposite directions.
 15. Themethod of claim 10, wherein the one or more air blowers directing airtoward the second superabsorbent material delivery conduit are directair toward the second superabsorbent material delivery conduit inopposite directions.
 16. The method of claim 10, wherein the one or moreair blowers directing air in a direction toward the first superabsorbentmaterial delivery conduit are disposed between 10 mm and 100 mm from thefirst superabsorbent material delivery conduit.
 17. The method of claim11, wherein the one or more air blowers directing air in a directiontoward the second superabsorbent material delivery conduit are disposedbetween 10 mm and 100 mm from the second superabsorbent materialdelivery conduit.
 18. The method of claim 10, wherein the firstsuperabsorbent material delivery conduit and the one or more firstapplication nozzles dispensing the second adhesive are disposed within asuperabsorbent material delivery chamber.
 19. The method of claim 10,wherein the first quantity of superabsorbent material is applied ontothe base carrier sheet to have a first cross-machine direction maximumwidth, the second quantity of superabsorbent material is applied to thefirst quantity of superabsorbent material to have a second cross-machinedirection maximum width, and wherein the second cross-machine directionmaximum width is different than the first cross-machine directionmaximum width.
 20. The method of claim 19, wherein the first quantity ofsuperabsorbent material is applied onto the base carrier sheet to have aplurality of cross-machine direction widths, and wherein the secondcross-machine direction maximum width is less than or equal to a minimumcross-machine direction width of the applied first quantity ofsuperabsorbent material.